1、 AEROSPACE STANDARD SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, NI /CU, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 200 C MAX, 1X1 SEALANT OPENING AS81824/11Copyright 2016 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted,
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3、RESS: http:/www.sae.org ISSUED2011-11 REAFFIRMED2016-11 THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C1 FEDERAL SUPPLY CLASS 5940 AS81824/11 SHEET 1 OF 4 SAE Technical Standards BoardRules providethat:“This reportis publishedbySAE toadvancethestateoftechnicalandengineering sciences. The use of this re
4、port isentirely voluntary, andits applicability andsuitability for any particularuse, includingany patentinfringement arising therefrom,is the soleresponsibility of theuser.”SAE reviews eachtechnical reportatleast every fiveyears atwhichtimeitmay berevised,reaffirmed, stabilized,orcancelled. SAE inv
5、ites yourwrittencomments andsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS81824/11 RATIONALE AS81824/11 HAS BEEN REAFFIRMED TO COMPLY WITH THE SAE FIVE-YEAR REVIEW POLICY. NOTICE THE REQUIREMENTS FOR ACQUIRING TH
6、E PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECIFICATION SHEET AND THE LATEST ISSUE OF SAE AS81824. FIGURE 1 SEALING SLEEVE FIGURE 2 METAL CRIMP SPLICE STRIPE COLOR CODED IN ACCORDANCE WITH TABLE 1. (2PL) C.110 .080 A WIRE STOP D TYP INSPECTION WINDOW B E .950 MINIMUM ID 1.10 .05 COLOR CODED I
7、NSERT OR CIRCUMFERENTIAL STRIPE ON SLEEVE IN ACCORDANCE WITH TABLE 1. THE CONFIGURATION OF THE MELTABLE INSERT MAY VARY ACCORDING TO THE INDIVIDUAL MANUFACTURERS DESIGN. AEROSPACE STANDARD AS81824/11 SHEET 2 OF 4 SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, NI /CU, INSULATED, ENVIRONMENT RESISTANT, CLA
8、SS 1, 200 C MAX, 1X1 SEALANT OPENING TABLE 1 - CONSTRUCTION DETAILS PART NUMBER WIRE RANGE ID* a MIN b MAX A B C D E MAX COLOR CODE WEIGHT LB (Kg) per 1000 PCS MAX M81824/11-1 SEE TABLE 4 0.085 (2.16) 0.05 (1.27) 0.08 (2.03) 0.51 (13.0) 0.245 (6.22) 0.015 (0.38) RED 1.02 (0.46) 0.025 (0.64) 0.045 (1
9、.14) 0.075 (1.91) 0.49 (12.4) 0.225 (5.72) M81824/11-2 SEE TABLE 4 0.11 (2.79) 0.069 (1.75) 0.107 (2.72) 0.585 (14.9) 0.28 (7.11) 0.02 (0.51) BLUE 1.61 (0.73) 0.025 (0.64) 0.064 (1.63) 0.1 (2.54) 0.565 (14.4) 0.26 (6.6) M81824/11-3 SEE TABLE 4 0.17 (4.32) 0.102 (2.59) 0.155 (3.94) 0.585 (14.9) 0.28
10、(7.11) 0.05 (1.27) YELLOW 2.72 (1.24) 0.025 (0.64) 0.097 (2.46) 0.146 (3.71) 0.565 (14.4) 0.26 (6.6) INNER DIAMETER (I.D) a - AS RECEIVED b - AFTER UNRESTRICTED RECOVERY THROUGH THE MELTABLE MATERIAL. REQUIREMENTS 1. MATERIALS COPPER: ASTM B280, ASTM B75, OR ASTM B187 INSULATION SLEEVE: HEAT SHRINKA
11、BLE CROSS-LINKED FLUROPOLYMER (PERFORMANCE REQUIREMENTS PER SAE AMS-DTL-23053/18) SEALING MATERIAL: MODIFIED THERMOPLASTIC FINISH NICKEL PER SAE AMS-QQ-N-290 2. DIMENSIONS DIMENSIONS ARE IN INCHES. METRIC EQUIVILENTS (TO THE NEAREST 0.01 MM) ARE GIVEN FOR GENERAL INFORMATION ONLY AND ARE BASED UPON
12、1 INCH = 25.4MM. UNLESS OTHERWISE SPECIFIED, TOLERANCES ARE .005 (0.13MM) FOR THREE PLACE DECIMALS AND .01 (0.25 MM) FOR TWO PLACE DECIMALS. THE AVERAGE OF DIMENSION “A” AND “B” MUST BE WITHIN SPECIFICATION LIMITS. “B” DIAMETER SHALL NOT INCLUDE COLOR STRIPE. 3. SEALING SLEEVE THE SEALING SLEEVE COM
13、PONENT OF THE SPLICE ASSEMBLY SHALL MEET THE REQUIREMENTS OF 3.5.1 OF AS81824 WHEN CONDITIONED AT 200 3 C FOR 16 .5 HOURS. 4. TEMPERATURE CYCLING THE SPLICES SHALL MEET THE REQUIREMENTS OF 4.8.6.3 OF AS81824 EXCEPT THAT THE TEMPERATURE FOR STEP 3 SHALL BE 200 +3-0 C. 5. CONTOUR THE CONTOUR OF THE SP
14、LICE MAY VARY FROM THAT SHOWN PROVIDED THAT THE SPLICE REMAINS WITHIN THE MAXIMUM ENVELOPE DIMENSIONS. 6. NO ETCHING OR SOLVENT TREATING OF THE ASSOCIATED WIRE INSULATION SHALL BE PERMITTED. 7. HEAT AGING SPLICES SHALL MEET THE REQUIREMENTS OF 4.8.6.7 OF AS81824 EXCEPT THAT THE SAMPLES SHALL BE COND
15、ITIONED AT 200 3 C. AEROSPACE STANDARD AS81824/11 SHEET 3 OF 4 SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, NI /CU, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 200 C MAX, 1X1 SEALANT OPENING 8. QUALIFICATION 8.1 TERMINATION TOOL: FOR QUALIFICATION TESTING, ONLY SPLICE ASSEMBLIES MADE WITH WIRE CONFORMIN
16、G TO AS22759/12 SHALL BE TESTED WITH THE METAL SPLICE. THE SEALING AND INSULATING SLEEVE SHALL BE INSTALLED WITH THE APPLICABLE HEAT TOOL. FOR CRIMPING TOOLS SEE TABLE 2. THE RECOMMENDED CRIMP TOOL IS THE M22520/37-1, BUT THE M22520/5 AND M22520/10 CRIMP TOOLS WITH DIES LISTED IN TABLE 2. MAY ALSO B
17、E USED. TABLE 2 CRIMP TOOLS SPLICE PART NO. BASIC CRIMP TOOL FRAME NO. DIE NO. M81824/11-1 M81824/11-2 M22520/5-01 M22520/5-103M22520/10-01 M22520/10-104M22520/37-01 NOT REQUIRED M81824/11-3 M22520/5-01 M22520/5-102M22520/10-01 M22520/10-103M22520/37-01 NOT REQUIRED 8.2 SAMPLE PREPARATION: SAMPLES S
18、HALL BE PREPARED IN ACCORDANCE WITH TABLE 3. TABLE 3 QUALIFICATION TEST SAMPLE WIRE SIZE FOR SINGLE AND DOUBLE TERMINATION PART NUMBER SINGLE WIRE (SIZE) MULTIPLE WIRE SIZE (QTY) ON BOTH ENDS MIN MAX MIN SAMPLE COMBINATION MAX SAMPLE COMBINATION M81824/11-1 26 20 26(2) 26(1) + 24(1) M81824/11-2 20 1
19、6 26(1) + 22(1) 22(1) + 20(1) M81824/11-3 16 12 24(1) + 18(1) 22(1) + 12(1) 8.2 QUALIFICATION OF MULTIPLE WIRE COMBINATION SHALL BE TESTED IN ACCORDANCE WITH SAE AS81824 EXCEPT AS FOLLOWS: 8.3.1. VOLTAGE DROP (REFERENCE: SAE AS81824 PARAGRAPH 4.8.1): REFERENCE VOLTAGE DROP SHALL BE DETERMINED BY AVE
20、RAGING 4 SAMPLES OF APPLICABLE COMBINATION WIRES WITH SOLDERED CRIMP SPLICES. THE REFERENCE MILLIVOLT SHALL BE MADE BY PUNCTURING THE LARGEST WIRE INSULATION ON BOTH SIDES OF THE CRIMP 1/16 INCH BACK FROM THE ENDS OF THE SEALING SLEEVE. 8.3.2. TENSILE STRENGTH (REFERENCE: SAE AS81824 PARA 4.8.5): TH
21、E TENSILE STRENGTH SHALL BE TESTED AS FOLLOWS: 8.3.2.1 SMALLEST WIRE ON EACH SIDE SHALL BE ATTACHED TO OPPOSING GRIPS OF THE PULL TESTER WITH THE SPLICE UNATTACHED IN THE APPROXIMATE CENTER, AND PULLED WITH SUFFICIENT FORCE* TO PULL ONE OF THE WIRES OUT OF THE SPLICE OR BREAK ONE OF THE WIRES, OR BR
22、EAK THE SPLICE. 8.3.2.1.1 THE PASS/FAIL CRITERIA FOR THIS TEST IS THE AS81824 ESTABLISHED MINIMUM STRENGTH FOR THE WIRE TYPE (PLATING) AND GAGE SIZE OF THE WIRE THAT PULLED OUT OR BROKE. IF THE SPLICE BROKE, THE TENSILE VALUE FOR THE SMALLEST WIRE ATTACHED TO THE PULL TESTER GRIPS WILL APPLY. 8.3.2.
23、2 ON A DIFFERENT BATCH OF SAMPLES THE LARGEST WIRE IN EACH OF THE SPLICE SHALL BE ATTACHED TO OPPOSING GRIPS OF THE PULL TESTER WITH THE SPLICE UNATTACHED IN THE APPROXIMATE CENTER, AND PULLED WITH SUFFICIENT FORCE* TO PULL ONE OF THE WIRES OUT OF THE SPLICE OR BREAK ONE OF THE WIRES OR BREAK THE SP
24、LICE. 8.3.2.2.1 THE PASS/FAIL CRITERIA FOR THIS TEST IS THE AS81824 ESTABLISHED MINIMUM STRENGTH FOR THE WIRE TYPE (PLATING) AND GAGE SIZE OF THE WIRE THAT PULLED OUT OR BROKE. IF THE SPLICE BROKE, THE TENSILE VALUE FOR THE LARGEST WIRE ATTACHED TO THE PULL TESTER GRIPS WILL APPLY. * HEAD SPEED PULL
25、 RATE: 1 1/4 INCH PER MINUTE 8.3.3. CURRENT CYCLINIG (REFERENCE: SAE AS81824 PARAGRAPH 4.8.2): THE CURRENT CYCLING TEST SHALL BE PERFORMED AS FOLLOWS: 8.3.3.1 SAMPLES SHALL BE ATTACHED TO 3 FOOT LENGTH OF THE LARGEST ACCOMMODATED SINGLE WIRE ON ONE SIDE AND MAXIMUM ACCOMMODATED MULTIPLE WIRES ON THE
26、 OTHER SIDE. THIS PATTERN SHALL ALTERNATE TO CONNECT THE REQUIRED NUMBER OF SAMPLES PER TABLE III OF SAE AS81824 QUALIFICATION INSPECTION. THE CURRENT FOR THE MAXIMUM SINGLE WIRE AS DEFINED IN TABLE I OF SAE AS81824 TEST REQUIREMENTS SHALL BE APPLIED FOR THE NUMBER OF CYCLES AND DURATION DEFINED IN
27、PARAGRAPH 4.8.2 OF SAE-AS-81824. AEROSPACE STANDARD AS81824/11 SHEET 4 OF 4 SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, NI /CU, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 200 C MAX, 1X1 SEALANT OPENING 8.3.3.2 VOLTAGE DROP SHALL BE MEASURED FOR EACH WIRE AND COMPARED TO THE SOLDERED EQUAL CONFIGURATIO
28、N AS DESCRIBED IN PARAGRAPH 8.3.1. 8.3.4. INSULATION RESISTANCE AND DIELECTRIC WITHSTANDING VOLTAGE (REFERENCE: SAE AS81824 PARAGRAPH 4.8.3 AND 4.8.4) MEASUREMENTS SHALL BE PERFORMED ON THE LAREST WIRE ON EACH SIDE OF THE SPLICE. 9. NOTES INTENDED USE: THIS SPLICE IS INTENDED FOR USE IN MAKING ENVIR
29、ONMENTALLY PROTECTED PERMANENT JOINTS CONNECTING MAXIMUM OF TWO TO TWO WIRES (NO MORE THAN TWO WIRE INSERTED IN EACH END OF THE SPLICE) FOR WIRES RATED AT 200 C MINIMUM; NICKEL AND SILVER COATED CONDUCTORS; AND FALLING WITHIN THE DIAMETER RANGE SPECIFIED IN THIS SPECIFICATION SHEET. WHEN USING TWO W
30、IRES REFER TO TABLE 4 AND TABLE 5 BELOW FOR CMA RANGES. THE SPLICE MAY ALSO BE USED WITH WIRES RATED AT 135 C MINIMUM AND TIN PLATED CONDUCTOR. RECOMMENDED WIRE RANGE TABLE 4 - RECOMMENDED WIRE RANGE (REFERENCE) PART NUMBER SINGLE WIRE /1 MULTIPLE WIRE RANGE CMA (mm2) MULTIPLE WIRE TOTAL OD(OD1+OD2)
31、 MAX M81824/11-1 26-24-22-20 304 1510 (0.15 0.75) 0.085 (2.16) M81824/11-2 20-18-16 1058 2680 (0.53 1.34) 0.110 (2.79) M81824/11-3 16-14-12 2375 6755 (1.19 3.37) 0.170 (4.32) /1. FOR OVERLAPPING WIRE SIZES (E.G., SIZE 20 FOR M81824/11-1 AND M81824/11-2 AND SIZE 16 FOR M81824/11-2 AND M81824/11-3), T
32、HE SMALLER SIZE SPLICES ARE PREFERRED. I.E., FOR SIZE 20 AND SIZE 16 WIRES, M81824/11-1 AND M81824/11-2, RESPECTIVELY, ARE PREFERRED. TABLE 5. TYPICAL CONDUCTOR CMA (REFERENCE) SIZE 26 24 22 20 18 16 14 12 STRANDS 19 19 19 19 19 19 19 37 CMA 304 475 754 1216 1900 2426 3831 5874 (mm2) (0.15) (0.24) (0.38) (0.61) (0.95) (1.21) (1.92) (2.94)
